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lnstallation, Operating and

Maintenance I nstructions

,I COMPBESSED

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HPC Engineering PLC

. .
Victoria Gardens Burgess Hill West Sussex RH15 gRQ
.
Telephone: (0444') 241671 Fax: (0M4) 247304

lndex:041010
GL- Nr.: BA-SK1 9.1- 1 .9761 .3OO2o-00

Manufacturer:

:'
D-96410 Coburg . Postfach 2143 . Tel. (09561) 640-0 i'Fax.(09561) 640_190:.,;
.
 .dtr'* \

I(AESER
KOMPRESSOREN

Declaration of Gonformity
(( within the meaning of machinery directive 89/39ZEU, appendix ll A D
We hereby declare that the machine/unit of

type: stationary screw compressor unit

L '97 61 ' 30020
(with electric motor drive) Part number:
make: Kaeser serial number:
SK 19
model /t,tl-9 I o?
conforms, in the specification supplied by us, to the following relevant conditions,
in particular:

89l392tEU: Directive for machinery

73123lEU Directive for low voltage

87t404tEU: Directive concerning simple unfired pressure vessels

89l336tEU Directive concerning electromagnetic compatibility

Harmonised standards applied, in particular:

prEN 1012-l: Compressors - safery requirements

EN 292-1 and2: Safety of machinery

EN 294: Safety of machinery - safety distances

EN 286-1: unfired pressure vessels

EN 60204-1: Safety of machinery - electrical equlpment

EN 50081-2: Electromagnetic compatibility - radio interference transmission

EN 50082-2: Electromagnetic compatibility - radio interference suppression

National technical standards and specifications applied, in particular:

- Equipment safety act

- Equipment safety act regulations

Coburg 30.tr.1994
Location Date ve signature
(Dipl.-Wi.-lng. Thomas Kaeser)

KAESER KOMPRESSOREN GmbH Tel.: (0 95 61) 64Go Gesch6ftsl0hrung Dipl.-lng. Carl Kaeser, Dipl.-Wi.-lng. Thomas Kaeser
SiE Ca#Kaeser-Str. 26, D96450 Coburg Fax (0 95 61) 64G130 RG Coburg B 292
Tk 6632Al USt-ldNr.: DE132460321 :
n:Uokuumt\(x)le.d@
 IIAESER
KOMPRESSOREN

Screw Compressor
Model: SK 19
1t

Sound Pressure Level

Operational state of the compressor unit:
Full load, the compressor unit runs at: rated , rated pressure, rated capacity.

Setting up conditions:
Free field measurement

Statement of sound pressure level:

Measurementto DIN 45635 (measurement of on machines, compressors)
o 1 m distance
o 1.6 m height
a Related point of measurement: centrally front of the cooling air outlet
Highest sound pressure value 70 dB (A)

KAESER KOMPRESSOREN GmbH

D-96410 Coburg , Postfach 2143 . Tel. (09561) 640-0 . Fax.(09561) 640-130

;i
 KAESER
COMPRESSORS '1r'.1
Table of Contents
Chapter - Page

1 TechnicalSpecification 1-1
1.1 Compressor Unit . 1-1
1.2 Motor 1-1
1.3 Electrical Connection .. 1-l
1.4 Setting Value of the Mains Pressure Switch . . . . . .... 1 - 1

1.5 Setting Value of the Safety Relief Valve .... 1-2

1.6 lnstallation Requirements . . .. . ...'. 1 - 2
1.7 OilVolumes .... 1-2
1.8 Compressor Oil Specifications .... 1-2
1.9 Greasing the Electrical Motor 1-3
1.10 DimensionalDrawing 1-3
2 Safety Regulations .. Z -4
2.1 Explanation of Symbols and References .. 2-4
2.2 General Notes on Accident Prevention Regulations . . 2-4
2.3 Accident Prevention Regulation 10.0 "Power Driven work Units" (vBG s) .. .. . 2 - 4
2.4' Accident Prevention Regulations 13.4 "Compressors" (VBG 16) . 2- s
2.5 GeneralReferences 2-5
2.6 Spare Parts .2-5
2.7 Compressed Air Station .2-5
3 General 3-7
3.1 Correct use of the Compressor 3-7
3.2 lncorrect use . . ..3-7
3.3 Compressed Air Treatment . . . ..3-7
3.4 Copyright ..3-7
4 Transport 4-8
4.1 Transport lnstructions 4-8
4.2 Packaging 4-8
5 Construction and Operation 5-9
5.1 Principle of Compression .. .. ... tr-o
5.2 Short Description . tr-o
5.3 Pipe and lnstrument Flow Diagram (P & I Diagram) tr-o
5.4 DUAL Control . . .... ...5-10
6'lnstallation ..... 6-11
6.1 lnstallation Requirements ...6-11
6.2 Connection of the Compressed Air Supply ...6-12
6.3 Electrical Connection ...6-12
7 Putting into Operation Z - 19
7.1 Points to be Obserued before Putting into Operation . . . . . . 7-13
7.2 Points to be Observed before Starting the Compresdor Unit: i:.. 7 : 13

I
I.
 r(AESER
COMPRESSORS
Table of Contents
Chapter - Page

7.3 Functional Check of the Door lnterlock Switches . . . . . 7-14

7.4 Direction of Rotation Check 7-14
7.5 Setting up the Overload Flelay ...7-14
7.6 lnitial Measures before Putting the Compressor Unit into Operation ...7-15
7.7 Setting up the Off-Load Running Timing Relay for
-
Off-Load Running lntermittent Control 7 -15
7.8 Setting up the Line Pressure Switch 7-16
7.9 Putting into Operation again after an Oil Change or Temporary Storage 7-17
I Operation 8-18
8.1 ControlPanel 8-18
8.2 Starting and Stopping the Compressor Unit.. ... 8-18
8.3 Safety System: KAESER CONTROL 8-18
8.4 Remote Contact Thermometer . . . 8-19
I Maintenance 9-21
9.1 Observe the following instructions during all maintenance and servicing work: 9-21
9.2 Regular Maintenance 9-21
9.3 Checking the Drive Belt Tension . .
I'
9-22
9.4 Drive Belt Change . : 9-23
9.5 Cleaning or Renewing the Filter Mat 9-23
9.6 Oil Filter Change 9-24
9.7 OilTop Up ......... $-
9-25
9.8 Cleaning the AiriOilCooler . .
::.st:
9-27
9.9 Greasing the Electric Motor .. i.. r. .. ....i.'_.'. -.. 9 - 29,.
9.10 oilChange(oilSeparatingTankandoilCooler)..;'.,.(..j..... 9-29
9.11 TestingtheSafetyValveontheOil Sepa?atorTank. :f..'.;. .:......... 9-32
9.12 Cleaning or Renewing the Air Filter 9-331
9.13 Changing the Oil Separator Cartridge 9-34
10 Spare Parts and After Sales Seruice 10-36
10.1 Service parts and expendable parts .. . 10 - 36
11 Appendix.. 11 -97
11.1 Electrical Diagram 11 -37
11.2 Maintenance Schedule . .. 11 - 38

I
I .'I

T
KAESER
COMPRESSORS )
Technical Specification
I 1 Technical Specification .,,
T a

1.1 Compressor Unit

T Maximum gauge working pressure . .. . . 10 bar
Free air delivery at max. gauge working pressure . . . 1,5 m3/min

I Operatingtemperatureapprox. ...75 - 85
Weight ...270
oc
kg

I Noise levelto CAGI-Pneurop

at 1 metre distance (free sound field measurement)
. ..67 dB(A)

Drawings:
T Dimensionaldrawing ..... T7471.4
P& lflow chart FSK1 gSTL-09e3/00001
(Pipework and instrument flow chart)
T Electrical diagram sK19-0994/00200

I 1.2 Motor

I Compressor motor:
Rated power
Rated speed
11 kW
3000 min-1
I Max. cut-in frequency per hour
lP 54
.. 15 times
V belt set:
T
6.2502.0
,l 1.3 Electrical Connection
Mains voltage ..400 V 3-lPE
T Frequency ..... ...50 Hz
Max. mains fusing (slowblow or glclass) ...35 A

T Power supply cable core cross-section .4x6 mm2

(CU multiple core cable)
Maximum rated current lru ..... 24A
T 1.4 Setting Value of the Mains Pressure Switch

I o"
t-

I 876
114
o
A Possib/e seftrno ranoe
pres-sure -switch
of the line

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= A ,/

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4 6 I 10 12 1416 18
Cut-out pressure > bar (g)
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 KAESER
COMPRESSORS
Technical Specification

Settings made at the works:

Cut-in pressure ... 9,2 bar
Cut-out pressure .... 10 bar
Differential pressure Ap 0,8 bar

1.s Setting Value of the Safety Relief Valve

Activatingpressure ...11,S bar

1.6 lnstallation Requirements

Max. height above sea level of the place of installation 1000 m
Min. ambienttemperature . . . . ....... Ia or^
V
Max. ambienttemperature ..... .... 40 "c
Min. cooling airlinlet air temperature ..3 0c
Max. cooling airlinletairtemperature . .. .. . .40 0c
Air inlet opening 0,3 m2
Exhaust air for solution A (see chapter 6.1):
Forced ventilation with exhaust ventilator . . 4000 m3/h at 10 mm WS
Exhaust air for solution B (see chapter 6.1):
Exhaust air used for space heating
Heatingductbxh.. 355 x 510 mm

1.7 OilVolumes
Totalvolume of oil .12 I

After oil change or after long period of storage ,,..

Partvolumefortoppinguptheairend ....... O,S I

1.8 Compressor Oil Specifications

It is important that the correct oil is used in Plusair screw compressors to ensure optimum
performance and reliability. HPC Plusair screw compressor oil has been proven bver many
years to have the properties necessary for trouble free running and minimum filter conta-
mination.
The compressor unit will be supplied filled with HPC Plusair screw compressor oil. lt is
strongly recommended that this type of oil continues to be used. HPC Plusair screw com-
pressor oil is available from HPC distributors or direct from HPC Engineering PLC, Vil<toria
Gardens, lndustrial Estate, Burgess Hill, west sussex, RH 15 9Re. Telephoie 04444 24
1671. Fax 0M44247304.
Ditferenttypes of oil may not be mixed. When changing from one type to dnother, all oil in
the oil/air sump and cooler must be drained.

Attention! To maintain warranty and product liability use Hpc plusair screw com-
pressor oil.only.

The oil used for cooling the scew compressor during operation must have the following
properties: ' ;

1-2
 I(AESER
COMPRESSORS
Technical Specification

o high ageing resistance

o high dispersive power
o low emulsifiability
o minimum foaming properties D

o Basic oil: Solvent ratfinate

o Hydraulic or turbine oil: viscosity class VG 46
o Viscosity at 40'C: approx. 42-50 cSt
o Flash point, surface temperature: above +200'C
o Pour point: at least +5'C below lowest ambient temperature

1.9 Greasing the Electrical Motor

Renew the compressor motor gearing:
Under normal operating conditions, after 11000 h*
(ambient temperature up to 25'C)
Under unsuitable conditions, after 5500 h*
(ambient temperature up to 40'C)
but at the latest after 3 Years
*operating hours
-*i[u'

1.10 Dimensional Drawing

(see following page)

., 1-3
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, SK 19 SK26 AS.419tt
Ers otz. f iir: T ?t-?i.3'i o1pr.: ?,#

o
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orr cenhe cmling

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ouitet otr L

inlet
rJ.1

35 660

o oxl+ 0 45 5

-t

o t0x
instcument one I
P 936

P 6x 510 .:._--r7
fi /l
e lec tricot ccnnecf i ons ll /ii
P 921

O ,/ compressed oir
outtet 61
105

M 1:20
 I(AESER
COMPRESSORS
Safety Regulations

2 Safety Regulations
Read this seruice manual carefully and observe cautionary references before putting this
compressor unit into operation and before carrying out any maintenance on the unit.

2.1 Explanation of Symbols and References

A This symbol ls placed before all references to safety where danger to

life and Iimb can occur during work. lt ls especlally important that
these rules are observed and that extreme care is taken in these
cases. For their own protection, inform all other users of these safety
rules. Observe generalsafety and accident prevention regulations as
well as the safety rules laid down in this service manua!.

Attentionl This symbol is at points where considerable attention must be paid so

that recommendations, regulations, references and correct sequence
of work are adhered to and that damage and/or destruction of the com-
pressor unit and/or other equipment is prevented.

E This symbol indicates operations to be carried out by the operator or

service technician.

o This bullet identifies listings.

Abbreviations:
VBG Association of Employers Liability lnsurers (AELI)
UW Accident Prevention Regulations (APR)

2.2 Generat Notes on Accident Prevention Regulations

The terms 'U\ y'' and 'VBG" are abbreviations and refer to specific accident prevention
regulations of the Federal Republic of Germany.
Should any one of the regulations referred to in this service manual not conform to local,
laMul regulations then the stricter regulation applies.
Users of compressor units outside the Federal Republic of Germany are therefore obli-
gated to check the valid accident prevention regulations concerning the compressor unit in
the country of use. lf these regulations are stricter than German regulations, corresponding
measures must be taken before the compressor unit is.put into operation.

2.3 Accident Prevention Regutation 10.0 "Power Driven Work Units,,

(vBG 5)
Attention! According to the German accident prevention regulations VBG 5, para-
graph 12 (DlN VDE 0113 Part 1 or IEC 2O4 - I and European Standard
'EN
60204 - 1) the operator of a compressor station is obtigated to
carry out the following measures:

Compressor units fitted with a drive motor of drive power 3 kW or

more and a current rating of 16 ampere or more must be installed with
:r a lockable mains isolating switch (DlN VDE 0660, DIN VDE 0100) and
cut-out fuses.
See chapter 1.3 for details of the mains lsolating switch, core cross-
sections and fuses.

{
2-4
 I(AESEII
COMPRESSORS
Safety Regulations

2.4 Accident Prevention Regulations 13.4 "Compressors" (VBG 16)

Attentionl We refer especially to paragraph 12: General installation and condition
of the lnstallation space.

We also recommend observation of the following:

o Allow no open flame and flying sparks in the place of installation.
o During any necessary welding on the compressor unit or nearby ensure that sparks or
high temperatures cannot cause fire or explosion.
o Ensure that the compressor unit is fed with clean air without any damaging compo-
nents.
o Do not allow the maximum ambient temperature to be exceeded (see chapter 1.6),
otherwise special measures must be agreed between the manufacturer and the cus-
tomer.
o Carry out oil changes according to the service manual but at least once annually.
o Do not mix cooling oils of different types.
o To avoid build-up of condensate in the oil circulation, maintain and monitor the oper-
ating temperature according to the manufacturer's specifications.
o Use only cooling oils recommended by the manufacturer.
o lf maintenance work is carried out on any part of the oil circulation system, top up the
oil in the oil separatortank to the maximum level, run the compressor and keep it
under constant observation for a short period. Check the oil level again and top up
with oil to replace the oil taken up by the piping and the cooling system.

2.5 General References

A Work on power driven systems may only be carried out by trained or

specialised personnel (see UW 10.0).

Before work is carried out on electrical systems, carry out the follow-
ing measures in the sequence shown.

1. Switch off all phases

2. Ensure the unit cannot be switched on again

3. Check that no voltage is present

Discharge or shut otf pipework under pressure if not stated otherwise

in the seruice manual.

Attention! Any alterations or reconstruction carried out without consultation with

and withoutthe previous consent of I(AESER KOMPRESSOREN wil!
invalidate the warranty.

2.6 Spare Parts

Safe and reliable operation of the compressor unit is guaranteed only with KAESER original
spare parts and I(AESER SIGMA compressor oil.

2.7 Compressed Air Station

lf a compressed air station is extended or changed, check the blowotf pressure of the
safety valves on the air receiver tanks and in the pipework before the new compressor unit
is installed.

2-5
 I(AESER
COMPRESSORS
Safety Regulations

lf the blowotf pressure is too low, fit a safety valve with correspondingly higher blowoff
pressure..
I
I I(AESEII
COMPRESSORS
General
t 3 General
,I
I 3.1 Correct use of the Compressoi
The compressor unit is intended solely for the purpose of generating compressed air. Any

I further use outside of this purpose is considered incorrect. The manufacturer cannot ac-
cept liability for any damage caused by such incorrect use; the user alone is liable for any
risks incurred.

I Correct use of the compressor also encompasses adherence to the installation, removal,
commissioning, operational and maintenance conditions laid down by the manufacturer.

t 3.2 lncorrect use

T A Never dlrect compressed air toward persons. Gompressed air is a con-

centrated form of energy and as such is dangerous to life.

T 3.3 Compressed Air Treatment

I Never use compressed air from oil injected compressor units for
breathing purposes and production methods where the air has direct
contabt with food, without sublecting the compressed air to additional
treatment.
T

t 3.4 Copyright
The copyright of this seruice manual is the propefi of the firm of IGESER KOMPRES-
SOREN. This service manual is intended for operating personnel, maintenance persohnel
r' and supervisory personnel use only. lt contains instructions and technical diagrams that
may not be copied, either completely or partly, distributed or evaluated by unauthorised

I persons for the purpose of competition, or divulged to any other third party.

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3-7
T

I Transport
KAESER
COMPRESSORS

4 Transport

4.1 Transport lnstructions

We recommend a fork lift truck or lifting equipment for transporting the compressor unit to
avoid damage to the cabinet and framework.

min.1000 mm

Do not exert anv side forces on the comDressor

unit when transporting with lifting equipment !

4.2 Packaging
A decisive factor in the type of packaging is the transport route. The packaging conforms
to the packaging regulations laid down by the German Federal Association of Wood, Pallet
and Export Packaging (HPE), and by the Association of German Mechanical Engineering
lnstitutes (VDMA), if not otherwise contractually agreed.

t
T

T 4-8
 I(AESER
COMPRESSORS
Construction and Operation

5 Construction and Operation

'
5.1 Principle of Compression
The stationary compressor unit is fitted with a single stage, oil-injected air end. Two ro-
tors, the driven male rotor and the female rotor, both mounted in roller bearings, are fitted
into the air end. As the rotors rotate, air is drawn into the upper side through the inlet port
and is compressed on the lower side. The oilthat is injected into the lower side absorbs
heat generated by compression, prevents metallic contact between the rotors, seals the
rotors and the housing from each other and also lubricates the roller bearings. The com-
pressed air and oil mixture leaves the air end via the discharge port.

1 2 3 4 5
1 Drive shaft 4 Male rotor
2 Oilinjection 5 Female rotor
3 Discharge port 6 Air inlet port

5.2 Short Description

The compressor block is driven via V-belts from an electric motor.
An oil separating cartridge is fitted into the oil separating tank allowing practically oil free
compressed air supply. t
The regulation of the compressor unit ensures that compressed air is generated within the
set pressure limits.
A safety function protects the compressor unit against failure of important systems through
automatic shut-down.
The fan ensures ventilation of the compressor unit and also sufficient cooling air for the
air-cooled oil cooler and air cooler.

5.3 Pipe and lnstrument Flow Diagram (P & I Diagram)

(see following pages)

5-9
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 I(AESEP
COMPRESSORS
Construct on and Operation

5.4 DUAL Control

I D
'ma(
e
:v, Pmin
OD

a
o-

I Fullload-
o
i
o
a Off-load
o running-
o
Time >
ln DUAL Control (combined off-load running and intermittent control) the compressor nor-
mally runs at full-load and off-load running or standstill.
Operation is controlled by a pressure switch within set limits (see chapter 1.4) between
full-load and off-load running.
lf the compressor runs for longer than a preset time period, (1) to (2) e.g. tr = 6 min, in
off-load running, the electric motor switches off completely (2). When the low pressure
switching point pr;n (3) is reached the motor will restart automatically. The pressure now
rises to the high switching point prr, (4) and the compressor runs in otf-load running.
Should, however, the pressure drop within a shorter time period (4) to (5) e.9.tz = 3 min
again to pmin (5), the compressor willautomatically switch from otf-load running to full-
load.

5-10
 I(AESE
COMPRESSORS
nsta lat on

6 nstallation

6.1 lnstallation Requirements

lnstallthe compressor according to the following diagram. Keep to the minimum distances
shown to allow free access to the compressor unit.
Adequate ventilation of the compressor space is ensured only if the minimum values (see
chapter 1.6) are adhered to.

rrr"tventilator
@ot o
o
c\l
(\l
Exhaust
channel .\
E
B
h +
+ I Air inlet
opening
< I

800 810

G1 air connection Electrical connection

A o
o
|()
B
+ +
b + *EN
< o
o
(\t
N
T mn. .s
I

I
550
I

I \

850
Measurements in mm

Solutlon A: Forced Ventllation

The ventilator intended for the compressor room must provide adequate ventilation in rela-
tion to the size of the compressor unit (see chapter 1 .6).
Solution B: Exhaust Air used for Space Heating
The hot air is forced through a conduit (see chapter 1.6) into the room to be heated.

Attention! Consult the manulacturer with regard to length of conduit and number
of pipe bends lor respective compressor units.
Safe operation of the compressor unit is guaranteed only il the temperature limits (see
chapter 1.6) of the ventilating air are kept to.

6 - 11
 I(AESE
COMPRESSORS
lnstal at on

6.2 Connection of the Compressed Air Supply

The unit is set up ready to operate. Connect the discharge outlet to the user pipework
using a flexible connection hose.

6.3 Electrica! Connection

A The connectlon to the electrlca! maln supply and the protectlve

measures taken are to be carried out to DIN VDE regulatlons and the
regulatlons of the local Electrical Supply Authorlty by an authorlzed
electrician.

The compressor is wired ready for connection to the main supplies. Feed the supply cable
with cores marked L1,12, L3 and PE through the cable inlet in the base frame into the con-
trol box and connect to the terminals marked L1,l.2,13 and PE in this box.
Terminals for changeover switching and voltless contacts "Motor Running" and "Com-
-
pressor ON No Fault" are fitted as standard (voltless contacts are normally open and
breakproof).

Attention! According to the German accident prevention regulatlons VBG 5, para-

graph 12 (DlN VDE 0113 Part 1 or IEC 2O4 - 1 and European Standard
EN 60204 - 1) the operator of a compressor station ls obligated to
carry out the followinryeasures:

Compressor units fitted with a drive motor of drive power 3 kW or

more and a current rating of 16 ampere or more must be installed with
a lockable main isolating switch (DlN VDE 0660, DIN VDE 0100) and
cut-out fuses.
The construction of the main switch is dependent on the max. nominal
current lx ?ccording to operational category AC 23 (see chapter 1.3).

The recommended cross sections ol the necessary cables and the rat-
ings of the fuse cut-outs are given in chapter 1.3.

Attention! The cross-section of the supply cable and fuse ratings are specified
according to DIN VDE 0100 part 430 and 523 for an ambient tempera-
ture of 30'C. For other operating conditions, e.g. higher ambient tem-
peratures or longer supply lines (over 50 m) check and determine the
cross-section of the cable and the fuse ratings according to
DIN VDE 0100 and the local Electrical Supply Authority regulations.

lf circuit breakers are used instead of fuse links, it is essential that they are selected to suit
the incoming supply arrangement and the operating conditions of the compressor motor,
particularly in respect of the starting current.

6-12
 ti:

I(AESER
COMPRESSORS
Putting into Operat on

7 Putting into Operation

7.1 Points to be Obserued before Putting into Operation

Every compressor unit is given a test run in the factory and carefully checked before ship-
ment. The test run confirms that the compressor unit conforms to the specification data
and runs perfectly. However, independent of the checks made at the factory the com-
pressor unit could be damaged during transport. For this reason, we recommend that the
compressor unit is examined for such possible damage. Observe the compressor unit
carefully during the first hours of operation for any possible malfunction

Attention! lmportant functional components in the compressor unit (such as mini-

mum pressure check valve, safety relief valve, lnlet valve and com-
bination valve) are adjusted and fifted to precise setting up regula-
tions. Alterations to these components are not allowed without
previous consultation with the manufacturer.

A The minlmum pressure check valve, safety relief valve and inlet valve
are spring biased.

7.2 Points to be Obserued before Starting the Compressor Unit:

A ANY NON-OBSERVANCE OF THIS OR OTHER REFERENCES (WARN-

!NG; ATTENTION) CAN LEAD TO ACCIDENTS CAUSING INJURY TO
PERSONS OR DAMAGE TO EOUIPMENT.

The compressor unit restarts automatically after a power failure if the

air main pressure is lower than the pressure set on the air main pres-
sure switch.

Do not operate the compressor with open access doors as injury to

persons could occur through the drive belts and electrical equipment.

@ Remove all packaging materials, tools and transport securing devices on and in the
compressor unit.
o lt is expected that the user employs safe working techniques and that all lawful operat-
ing and safety regulations are followed when operating this compressor unit.
o The operator of this compressor unit is responsible for its safe operating condition.
o Do not operate this compressor unit in spaces where heavy dust conditions, poison-
ous or inflammable gases could exist.
o Do not connect the compressor unit to a supply voltage other than that stated on the
nameplate.
o lnstall the compressor unit in a space not subject to freezing temperatures, whereby
the air temperature conditions at the air-intake must be complied with (see chapter
1.6).
o lf exhaust ducting is provided, this must be at least the cross section of the cooler ex-
haust area in size and may not exceed the max. admissible pressure-loss defined by
the manufacturer.
o During installation of the compressor unit, ensure that a distance of at least 0.5 metre
is kept between the air intake of the unit and any wall.
r Check the oil level in the oil separating tank (see chapter 9.7).

7-13
 I(AESE
COM ESSORS
Putt ng into O perat on PR

@ Check the tension of the drive belts (see chapter 9.3).

@ The stopcock (6.6, see chapter 5.3) must be closed.
v The stopcock (20, see chapter 5.3) must be open.

A Carry out the following work only when power ls removed from the
compressor unit.

Check all screws on the electrical connectlons for tightness and

tlghten lf necessary (carry out thls check again after 50 operating
hours).

o Check that the air end rotates in the correst direction (see chapter 7.4).
o Do not switch the compressor unit off with the main supply switch when running under
load (see chapter 8.2).
o This compressor is fitted with a running-in oil fiiter cartridge. Replace the filter car-
tridge after the running-in period of 200 hours (see chapter 9.6).

7.3 Functional Check of the Door lnterlock Switches

It ls not permitted to operate the compressor unit with a malfunctioning
door lnterlock swltch.

w Carry out a visual and functional check of the door interlock switches.

1 Door interlock switch

7.4 Direction of Rotation Check

Attention! The compressor is wired for connection to a clockwise phase se-
quence.

A check of the direction of rotation can be made by testing the phase sequence.
Arrows showing the direction of rotation are located on the motor and on the air end hous-
ing.
lf the direction of rotation is incorrect, change over the supply conductors L1 and L2.

Attentionl lf the air end rotates in the wrong direction, the compressor is auto-
matically shut down by the pressure switch (4.2, see chapter 5.3).

7.5 Setting up the Overload Relay

A Disconnect the supply voltage to the unit by switching off the main
supply switch and ensure that the switch cannot be switched on again

7-14
 KAESEII
COMPRESSORS
Putt ng into Operation

before any adlustments are carried out on the compressor unlt. See
chapter 2.3tor the miln supply swltch.
The relay is set to the standard adjustment at the factory.
Compressor motor: star-delta start
ln the star-delta configuration the phase current is fed via the overload current trip. This
phase current is 0.58 times the nominal motor current.
For the nominal motor current see motor nameplate.
Setting-up values:
The value can be set to a maximum ol 1Oo/o higher than the calculated phase current to
prevent the overload trip operating under voltage fluctuations.

1 Motor phase current adjustment

2 Reset button

7.6 lnitial Measures before Putting the Compressor Unit into Operation

A Disconnect the supply voltage to the unit by switching off the main
supply switch and ensure that the switch cannot be switched on again
before any adjustments are carried out on the compressor unit. See
chapter 2.3tor the main suppty switch.
Extension of start period during the first start-up
@ lncrease the period of the timing relay K1 .1T to 20 seconds when starting the com-
pressor for the first time. This avoids compression of the intake air during the start pro-
cedure. Shortly before the end of thd 20 second period, switch off the compressor unit
(see chapter 8.2).
@ Set the timing relay K1 .1T back to the normal starting period of 6 seconds before oper-
ating the compressor any further.
This procedure ensures that the oil cooler and all oil pipes are filled with oil without en-
dangering the compressor air end.

A The compressor unit starts automatically again after a power fallure

provlding the line pressure is lower than setting on the Ilne pressure
switch.

7.7 Setting up the Off-Load Running Timing Relay for Off-Load Running -
lntermittent Control

A Disconnect the supply voltage to the unit by switching off the main
supply switch and ensure that the swltch cannot be switched on again

7-15
 ESE
COMPRESSORS
Putting into Operat on

before any adlustments are carrled out on the compressor unlt. See
chapter 2.3lor the maln supply swltch.

The off-load running timing relay is situated in the control cabinet (range of adjustment
1.5 to 30 minutes). The off-load running phase should be set so that the maximum cut-in
frequency of the motor (see chapter 1.2) is not exceeded.

7.8 Setting up the Line Pressure Switch

A Disconnect the supply voltage to the unit by swltching otf the main
supply switch and ensure that the swltch cannot be switched on again
before any adjustments are carried out on the compressor unit. See
chapter 2.3lor the main supply switch.

Setting the switching differential on the pressure switch for limiting the cut-in frequency.
The cut-ln frequency from on-load to off-load running is limited to max. twice per
minute.
The cut-in frequency can be reduced to a limited degree by increasing the switching dif-
ferential.
lf this measure is insufficient, install a larger series connected air receiver to provide more
butfer capacity.
See chapter 1.4tor the factory setting of the pressure switch and the pressure diagram.

Attention! The pressure adlustment ls possible on a fitted, pressurised switch

only.

1 Handwheel
2 Locking pin

lncrease cut- out pressure:

s Turn the handwheel to the right

Decrease cut-out pressure:

tr? Turn the handwheelto the left

7-16
 I(AESE
COMPRESSORS
Putting into Operation

To lncrease the pressure dlfferentlal between cut-ln and cut-out:

w Remove the locking pin

@ Depress the handwheel and turn to the left

@ lnsert the locking pin

To decrease the pressure dlfferential between cut-in and cut-out:

B Remove the locking pin

B Depress the handwheel and turn to the right

@ lnsert the locking pin

A Replace the pressure switch cover after every adjustment of the pres-
sure switch and before switching on the compressor.

7.9 Putting into Operation again after an Oil Change or Temporary Storage
Switch off the maln switch and secure agalnst switch-on.
A
Carry out the following measures after an oil change or a non-operative period of three
months or longer before starting the compressor:

Filling a small quantity of oi! into the air inlet connection

A The oil may only be added when the compressor unit is in a non-pres-
surised state.

@ When the compressor unit is stationary pour a quantity of oil (see chapter 1.7) into the
air intake port of the air end and manually rotate the air end in an anticlockwise direc-
tion with the drive belts.
@ To pour in the oil, unscrew the inlet valve above the air end and then pour the pre-
scribed quantity of oil into the air end.
B Screw the inlet valve back on again.

Attention! This oil must be of the same type as the oil used to operate the com-
pressor (see Iabel near the oil filler plug on the oil separator tank).

lf no additional oil is available, then remove this amount of oil from the
oil separatlng tank. See chapter 9.10 for thls procedure.

lf the compressor unlt was stationary for longer than 12 months,

further special measures must be carried out before putting the unit
back into operation. ln this case, consult the manufacturer first.

Before starting the compressor unit, carry out the measures described
in chapter 7.6.

7-17
 KAESE
COMPRESSORS
Operation

8 Operat on

8.1 Control Panel

1 Pressure gauge 4 "Start I Stop" controlswitch

2 Remote contactthermometer 5 I<AESER_CONTROL
3 Seruice hours counter 6 EMERGENCY STOP pushbutton

8.2 Starting and Stopping the Compressor Unit

Starting:

Attention! The compressor wil! start only if the line pressure is lower than the
pressure set on the line pressure switch.

@ Switch on the main supply switch.

E Turn the control switch (4)to the "Start" position.

Stopping:

Attention! Do not stop the compressor unit with the main supply switch. Always
start and stop the compressor unit principally with the control
switch (4).

@ Turn the controlswitch (4) to the "Stop" position.

@ Switch off the main supply switch and secure against switch-on.
See chapter 2.3 forthe main supply switch.

8.3 Safety System: KAESER CONTROL

The green light emitting diode "1" is illuminated if the compressor unit is running or ready
for operation. lt is extinguished if a fault is apparent.
A fault detected by the control functions
2,3, 4 and 5 will shut down the compressor unit
immediately, accompanied by an appropriate alarm indication.

8-18
 T(AE
COM
ER
ESSORS
PR
Operat on

idA[s[.t1 c0$,tTtici.

ll !,... r,: r

2 Overload trip of the compressor motor

shuts down with excess motor current.
When the fault is removed, press the overload trip reset button.
3 Remote contact thermometer for detection of excess discharge temperature (5, see
chapter 5.3).
The compressor unit is shut down if a discharge temperature of 100"C is reached.
4 Pressure switch (4.2, see chapter 5.3)
shuts down the compressor unit if the drive belts slip otf the pulley or break and at in-
correct direction of rotation.
5 Spare.

"EMERGENCY STOP Pushbutton"

lf the EMERGENCY STOP pushbutton is pressed, the compressor unit is shut down and all
LED's on the IGESER CONTROL or all recording LED's illuminate (see chapter 11.1).
Reset the compressor unit after the fault is removed.
@ Reset the EMERG. STOP push button by turning the latched push button in the direc-
tion of the arrow.
@ Reset the compressor by turning the control switch (see chapter 8.1) from "Start" to
"Stop".
The compressor unit is now ready to restart.

Door interlock switches with shut-down function when access doors are opened
lf the access doors are opened during compressor operation the compressor is shut-
down by the associated door interlock switch.
lf the door is closed again, the contact in the interlock switch closes. After the compressor
is reset by turning the control switch (see chapter 8.1) from "Start" to "Stop", it can be re-
started again.
See chapter 7 .3 lor the location of the door interlock switches.

8.4 Remote Contact Thermometer

lf the discharge temperature directly after the air end reaches 1OO.C, the remote contact
thermometer (5, see chapter 5.3) activates.
Activation of the remote contact thermometer causes a compressor unit shut-down,
coupled with appropriate indication on the IGESER coNTRoL (see chapter 8.3).
s Search for and remove the cause of the fault.

Possible causes of the fault:

o Low oil

8-19
 !

t
I(AESER
COMPRESSORS
,d
,1

I
Operat on

o Cooling system fault

r Ambient temperature too high or too low
o Clogged filter mat, oilfilter or cooler
v When the fault is removed, reset the compressor unit by turning the control switch
(see chapter 8.1) from "Start'to "Stop".
Then restart the compressor unit again (see chapter 8.2).

8-20
 I(AESER
COMPRESSORS
Ma ntenance

9 Maintenance

9.1 Obserue the following instructions during all maintenance and seruicing
work:

A Work on power drlven equipment may only be carrled out by tralned or

speciallsed personne!, see UW 10.0 (VBG 5) or localaccldent preven-
tion regulations.

The compressor unit restarts automatically after a power failure if the

air main pressure is Iower than the pressure set on the air main pres-
sure switch.

Switch off and lock out the mains supply switch to secure against
switch-on (see chapter 2.3 tor malns supply switch).

Ensure that no maintenance personnel are working on the compressor

unit, that al! panels are screwed back on again and allaccess doors
are closed before restarting the compressor unit.

To start the compressor unit see chapter 8.2.

The venting nozzle required to vent the oil separating tank (for main-
tenance work such as topping up the oil, oil change and filter change)
is fltted to the hose coupling (2, see chapter 9.71.

Carry out a visual and functional check of the door interlock switches
after any maintenance and servicing work.

See chapter 7.3 and 8.3 for details.

9.2 Regular Maintenance

Period Work to be done see chapter

24 hours after first put- Check the belts 9.3
ting into operation

50 hours after first put- Check all electrical screw connections for tight-
ting into operation ness and tighten if necessary
+ 100 h to 300 hours Clean the filter mats* 9.5

200 hours after first Change the oilfilter 9.6

putting into operation

weekly Check the oil level 9.7

500 hours Check the tension of the drive belts 9.3

Clean or change the air filter* 9.12

1000 hours Check the oil cooler and air cooler for contami- 9.8
nation

1000 to 2000 hours Change the oil filter* 9.6

9-21
 I(AESER
COMPRESSORS
Ma ntenance

Period Work to be done see chapter

2000 to 3000 hours Change the oil separator cartridge* 9.13

2000 to 3000 hours or Change the oil* 9.10

at least annually

Annually Check all electrical screwconnections for tight-

ness and tighten if necessary

Check the safety valve 9.11

5500/1 1000 hours or at Have the compressor electric motor bearings 9.9
the latest every three replaced using the KAESER Service
years
* The maintenance period can vary depending on the cut-in frequency and environmental
conditions.
We urgently recommend that a record is kept of the maintenance work done (see chapter
11.2).

9.3 Checking the Drive Belt Tension

@ Switch off the compressor unit (see chapter 8.2).

A Switch off the main supply switch and secure against switch-on to
prevent accidents during maintenance.

Check the tension of the belt drive after the first 24 hours of operation and thereafter every
500 hours of operation.

1 Hexagonal nut
2 Hexagonal nut
3 Marking pin

9-22
 I(AESER
COMPRESSORS
a ntenance

The belt drive tension is automatically adjusted within a limited range by the pressure
spring of the belt tensioning device.
Re-tension the belt drive if the belts have stretched to the point where the marking pin (3)
is situated at the top end of its indicator slot.

lf thls is the case, proceed as follows:

w Open the left-hand access door.
w Loosen the hexagonal nut (1).
@ Tension the belt drive with the hexagonal nut (2) until the marking pin (3) is situated at
the bottom end of its indicating slot.
B Tighten the hexagonal nut (1) again.
B Close the lett-hand access door.

9.4 Drive Belt Change

w Switch off the compressor unit (see chapter 8.2) I

A Switch off the maln supply switch and secure against switch-on to
prevent accidents during maintenance.

@ Open the left-hand access door.

s Screw the hexagonal nut (2, see chapter 9.3) downwards.
B Screw the hexagonal nut (1, see chapter 9.3) clockwise untilthe V belts are loose.
E Remove the V belts.
@ Place the new V belts over the motor and compressor pulleys without straining them.
E Set the belt drive tension (see chapter 9.3).
@ Close the left-hand access door.
E Check the belt drive tension after two hours of operation and then again after 24 hours
of operation, as experience shows that the belts stretch mostly during this time period.

Attentlon! It is essential that replacement belts are a!! preclsely the same Iength
(each set) and absolutely oil-proof. For this reason we recommend
that only origlnal I(AESER drive belts are used.

9.5 Cleaning or Renewing the Filter Mat

Clean the filter mat every 100 to 300 service hours depending on the dust content of the
inlet air.
s Switch off the compressor (see chapter 8.2).

A Swltch off and lock out the maln switch to prevent an accidental com-
pressor run.

9-23
 KAESE
Ma ntenance COMPRESSORS

1 Filter mat
2 Holding frame
E Remove the holding frame.
E Open and close with a screwdriver.
0? The clamping frame sits securely after turning the snap fasteners by a % turn.

Cleaning:
Rinse the mat in water of approximately 40oC, if necessary with a mild washing powder.
The mat can also be tapped with the palm of the hand, cleaned with a vacuum cleaner or
blown out with compressed air. Rinse out oily dust with warm water using a mild solvent
additive.

Attention! lf the mat is heavily soiled or has been cleaned often (max. 5 times),
replace it.

9.6 Oil Filter Change

A Hot oll; beware of scalding.

During the running in period, a running-in oil filter cartridge is fitted to clean the oil sys-
tem.

Attention! Replace the running-in oil filter cartridge with the standard oil filter
cartridge after approximately 200 operating hours.

It is recommended that further oil filter cartridge changes are made every 1000 to 2000 op-
F erating hours but always at every oil change.

Removaland replacement of the oilfilter cartridge:

w Switch off the compressor with the control switch (see chapter 8.2).

A Switch off and lock out the main switch to prevent an accidental com-
pressor run.

r? Close the shut-off valve between the compressor and the user's pipework.
The oil circulation system of the compressor vents automatically.
r? Open the upper access door.

9-24
 KAESER
COMPRESSORS
Ma ntenance

@ The pressure gauge on the oil separator tank must indicate zero bar.

Oil mlst can escape durlng venttng of the oit separating tank.
A
w lnsertthe venting nozzle (2, see chapter 9.7) in the hose coupling on the oil separating
tank (the residual pressure in the oil separator tank escapes).

1 Oilfilter cartridge
2 Turn in this direction to unscrew the cartridge
@ Twist the used or contaminated oil filter cartridge anticlockwise to remove and catch
escaping oil in a suitable container. Dispose of the oil according to environmental re-
gulations.
@ Clean the facing of the junction with lint free cloth.
trr Lightly oil the gasket of the new filter cartridge before screwing into position.
@ Screw in the new filter cartridge clockwise by hand until the gasket fits tightly.

Aftention! Do not use a tool as this may cause damage to the oil filter cartridge
and the gasket.

@ Check the oil level (see chapter 9.7).

@ Remove the venting nozzle from the hose coupling on the oil separator tank.
r? Close the upper access door.
B Open the shut-off valve between the compressor and the user's pipework system.

/f\ Carry out a trial run.

z-s.
When the operating temperature is reached (see chapter 1.1) shut
down the compressor (see chapter 8.2) and lock out the main switch to
prevent an accidental compressor run.

Carry out a visual check for leaks.

9.7 Oil Top Up

Check the oil level weekly with the oil level gauge when the compressor is shut down. lf
necessary top up the oilto the maximum level. Do not exceed the maximum level (centre
of the oil level gauge).

9-25
 KAESER
.Maintenance COM PR ESSORS

3 6
7
4 I
5
I

1 Nozle 5 Oilsepantortank
2 Hose coupling 6 Shut-oft cock
3 Filler stud (Oiltop-up) 7 Oildrain hose
4 Pressuregauge 8 Max. oillevel
9 Min. oil level

Venting the Compressor Unit:

@ Shut down the compressor unit (see chapter 8.2)

A Switch off and Iock out the main switch to prevent an accidenta! com-
pressor run.

s Close the shut-otf valve between the compressor unit and the user's pipework sys-
tem.
The oil circulation system of the compressor unit vents automatically.
w Open the left-hand and upper access door.
s The pressure gauge on the oil separator tank must indicate zero ban
/t\
z-s
Oi! mist can escape during venting of the oil separating tank.

r lnsert the venting nozzle (1) in the hose coupling (2) on the oil separating tank (the
residual pressure in the oil separator tank escapes).

To top up the oil:

A B_gfOre unscrewing the oil filler plug (3) on the oil separator tank it is
linperative that the compressor unit is vented.

@ Unscrew the oil filler plug (3) on the oil separator tank.
@ Top up the oilto the maximum mark.
r Check the gasket ring of the filler plug (3) for damage and then screw in the filler plug
(3).

-E Remove the venting nozzle (1) from the hose coupling (2).
w Close the lefi-hand and upper access door.
E Open the shut-off valve between the compressor and the user's pipework system.

Attention! After carrying out the oil change or oil cooler cleaning procedures run
the compressor unit up to operating temperature to ensure that the

9-26
 I(AESE
COMPRESSORS
Maintenance

comblnatlon valve closes and that the oll cooler ls fltled with oi!.

Subsequently vent the compressor unit and top up the oll agaln.

Attentlon! Always use the same brand and type of oil when topping up the oi!.
(see label on the oil separator tank).

lf the type of oll ls changed, draln the old oil completely and renew the
oilfilter.

Never use differing oiltypes

9.8 Cleaning the Air/Oil Cooler

Check the airloil cooler for contamination at least every 1000 operating hours. Heavy con-
tamination could lead to excessive temperature in the oil circulation system.
Removal of and cleaning the airloil cooler:
E Switch off the compressor unit (see chapter 8.2).

A Switch off and Iock out the main switch to prevent an accidental com-
pressor run.

r? Vent the compressor unit (see chapter 9.7).

1 Allen screw
2 Hose screw fitting
3 Pipe screw fitting
4 Pipe screw fitting

@ Open the left-hand and upper access doors

A When the compressor unit is vented, pressure is present in the pipe-

work system up to the mlnimum pressure check valve. For this reason
the compressor must be isolated from the compressed air plpework by
closing the shut-off valve between the compressor unit and the pipe-

9-27
 I(AESER
COMPRESSORS
Maintenance

work system. The alr cooler can subsequently be vented by cautlously

loosenlng the pressure llne lrom the compressed alr connectlon (4). !f
no shut-off valve ls avallable, vent the plpework completely. The pres-
sure gauge on the control panel must show zero bar.

w Unscrew the hose connector (2) and the pipe connector (3) from the combination
valve.
@ Unscrew the Allen screws (1) on the air cooler.
w Remove and check the O ring on the air cooler.
s Close up the pipes and openings on the combination valve, air cooler and oil cooler.

6
5

5 Hexagonal nut
6 Nlen screw

s Unscrewthe hexagonalscrew (5).

The Allen screws (6) are located behind two protective caps.

Attention! Before unscrewing the two AIlen screws (6) prop up the airloit cooler.

B Remove the protective caps and unscrew the two Allen screws (6)
@ Take out the airioil cooler.

Attention! A washing area provided with a waste water oil separator is required
when cleanlng the alrloll cooler.

B Clean the cooler cells with compressed air, water or steam jet.
w Reassemble in the reverse order.

Attentionl Seat the O rings correctly in the compressed air inlet of the air cooler
durlng reassembly.

@ Close the left-hand and upper access doors.

@ See chapter 9.7 for oiltop up.

Carry out a trial run.

A
When the operating temperature is reached (see chapter 1.1) shut
down the compressor unit (see chapter 8.2) and lock out the main sup-
ply switch to prevent an accidental compressor run.

9-28
 I(AESE
COMPRESSORS
Ma ntenance

Subsequently carry out a vlsual check for leaks.

w Open the shut-off valve between the compressor and the user's pipework.

9.9 Greasing the Electric Motor

Compressor motor:
The electrical motor bearings are permanently greased.

Attentlonl Have the motor bearings replaced using the KAESER Serulce in ac-
cordance with the maintenance schedule (see chapter 1.9).

9.10 Oil Change (Oil Separating Tank and Oil Cooler)

Carry out the oil change with the compressor at running temperature.

A Danger of scalding with hot oil.

Change the oil every 2000 to 3000 operating hours, depending on the contamination of the
inlet air, or at least annually.
lf the compressor unit operates in ambient temperatures close to the maximum admissible
ambient temperature (see chapter 1 .6), change the oil more often (e.9. after 1000 to 1500
operating hours).

Attention! Drain the oil out of the oil separating tank, cooler and the oil pipes
completely. See chapter 7.6 tor putting back into operation.

Oil change using separate pressurisation:

B Switch off the compressor unit (see chapter 8.2).

A Switch otf the main supply switch and secure against switch-on to
prevent an accidental compressor run.

@ Close the shut-off valve between the compressor and the user pipework system.
The oil circulation system of the compressor unit vents automatically.

9-29
 I(AESER
COM PR ESSORS
Ma ntenance

2
6

4
A +
5

B< +
1 Separate pressurization 5 Shut-off cock
2 Hose coupling A open
3 Pressure gauge B closed
4 Oil separator cartridge 6 Oildnining plug (oilcooler)
B Open the left-hand and upper access doors.
@ The pressure gauge (3) on the oil separator tank (4) must indicate zero bar.
E Close the stopcock (5).

Oil mist can escape during venting of the oil separator tank.

@ lnsert the nozzle (1, see chapter 9.7) into the hose coupling (2) on the oil separator
tank (4).
B Charge the tank via the nozle with external compressed air untilthe pressure gauge
(3) on the oil separator tank (4) indicates approximately 3 bar.

E Remove the nozzle from the hose coupling (2) on the oil separator tank (4).
s Prepare an oil container to catch the escaping oil.

Attentlon! Check the total oll capacity (see chapter 1.7).

@ Hang the oil drain hose in the container and secure.

@ Slowly open the ballcock (6, see chapter 9.7). The pressure in the oil separator tank
forces the oil out. When air escapes, close the ballcock immediately.
s Open the stopcock (5).
@ The pressure gauge (3) on the oil separator tank (4) must indicate zero bar.

Oil mist can escape during venting of the oil separator tank.

tr, lnsert the nozzle (1, see chapter 9.7) into the hose coupling (2) on the oil separator
tank (4) (the residual pressure in the oil separator tank escapes).
w Prepare an oil container for the oil cooler.

9-30
 I(AESEIT
Maintenance COMPRESSORS

@ Slowly unscrew the oil drain plug (6). The oil drains under the force of gravity.
@ Screw the oil drain plug (6) back in tightly.
See chapter 9.7 tor oil top up.
See chapter'l.7 lor the oil capacity.
@ Close the left-hand and upper access doors.
@ Open the shut-off valve between compressor unit and user's network.
@ Dispose of the used oil according to environmental regulations.
A Carrv out a trial run.
IA
When the operating temperature is reached (see chapter 1.1) shut
down the compressor unit (see chapter 8.2) and lock out the main
switch to prevent an accldenta! compressor run.

Aftenrards, carry out a visual check for leaks.

,i;
Oi! Change using own Compressed Air:
B Switch off the compressor unit with the control switch (see chapter 8.2)

A Swltch otf and lock out the maln swltch to prevent an accidental com-
pressor run.

@ Close the shut-off valve between the compressor unit and the user's pipework.
The compressor unit oilcirculation system vents automatically.
l

E Open the upper access door.

tr? The pressure gauge (3) on the oilseparatortank (4) must indicatezerobar.
B Close the stopcock (5).
@ Close the upper access door.
w Start the compressor unit (see chapter 8.2) and allow to run for approximately 30 sec-
onds.
E Stop the compressor unit (see chapter 8.2).

A Switch off and lock out the maln switch to prevent an accidental com-
pressor run.

s Open the left-hand and upper access doors.

E check the actual pressure on the pressure gauge (3). open the stopcock (5), let the
pressure on the pressure gauge (3) sink to approximately 3 bar and then close the
stopcock (5) again.
0? Prepare an oil container in readiness to catch the oil.

Attention! Check the total oil capacity of the compressor unit (see chapter 1.7).

@ Hang the oildrain hose into the container and secure.

s Slowly open the ballcock (6, see chapter 9.7). The pressure in the oil separator tank
forces the oil out. When air escapes, close the ballcock immediately.
B Open the stopcock (5).
B The pressure gauge (3) on the oil separator tank (4) must indicate zero bar.

9-31
 KAESER
COMPRESSORS
Ma ntenance

A Oll mlst can escape durlng ventlng of the oil separator tank.

w lnsert the nozzle (1, see chapter 9.7) into the hose coupling (2) on the oil separator
tank (a). The remaining pressure in the oilseparatortank escapes
@ Prepare the oil container in readiness to catch the oil from the oil cooler
@ Slowly unscrew the oil drain plug (6). The oil drains under the lorce of gravity.
B Screw the oil drain plug (6) back in tightly.
See chapter 9.7lor oiltop up.
See chapter 1.7 tor the oil capacity.
r Close the left-hand and upper access doors.
s Open the shut-off valve between compressor unit and user's pipework.
B Dispose of the used oil according to environmental regulations.
A
-:\ Carry out a triat run.

When the operatlng temperature ls reached (see chapter 1.1) shut

down the compressor unlt (see chapter 8.2) and lock out the main
switch to prevent an accidental compressor run.

Aftenrvards, catry out a vlsual check for leaks.

9.11 Testing the Safety Valve on the Oil Separator Tank

To test the activating pressure of the safety valve the compressor must be driven into a
higher discharge pressure than the maximum pressure set on the on the mains pressure
switch.
See chapter 1.5 for the safety valve activating pressure.

To avoid maladjustment of the mains pressure switch, carry out the test as outlined
below.
E Switch off the compressor unit (see chapter 8.2).

A Switch off and lock out the main switch to prevent an accidental com-
pressor run.

@ Close the shut-off valve between the compressor and the user's pipework.
tr? Open the upper access door.
@ Close the stopcock (5, see chapter 9.10) in the venting line.
s Close the upper access door.
r Start the compressor unit (see chapter 8.2) and allow to switch from full load to off
load running.
Because the venting line is closed, the pressure in the oil separator tank climbs slowly to
the activating pressure of the safety valve. The activating pressure is read on the pressure
gauge in the control panel.
B Stop the compressor unit (see chapter 8.2).

7fi
Z-:..1\
Switch ofl and lock out the main switch to prevent an accidental com-
pressor run.

9-32
 KAESER
COMPRESSORS
Ma ntenance

s Close the left-hand access door,

9.13 Changing the Oit Separator Cartridge ''t

Change the oil separator cartridge every 2000 to 3000 service hrs.
The life of the oil separator cartridge is strongly influenced by tEdegree of contamination
of the inlet air and the duratioh of the maintenance period forthdr and oilfilter cartridges.
B Stop the compressor (see chapter 8.2).

A Switch off and Iock out the main switch

pressor run.
to nt an accidental com-

E Close the shut-off valve between the compressor and the r's pipework.
The compressor unit oil circulation system vents automatically.

(D (D
(D (D
6
2
7
1

3
I
4
7
5 6

ffi
6
10
11

12

1 Noz.le 5 Cover 9 A-Ring

2 Hose coupling 6 Gaskef I0&sket
3 Pressure gauge 7 Metalclip 11 I*t trap screen filter
4 Hexagonal nut 8 Oil separating cariridge '12*rew fitting with jet

w Open the left-hand and upper access doors.

@ The pressure gauge on the oil separator tank must indicatercro bar.

Oil mist can escape when the oil separator is vented.

A

9-34
 aintenance COMPRESSORS

w lnsert the nozzle (1 ) into the hose coupling (2) on the oil separator tank (the tank is
thus vented).
w Unscrew the hexagonal bolts (4) and remove cover plate (5).
tr? Take out the old oil separator cartridge (8) together with the gaskets (6) and O ring (9).
Dispose of the old parts according to environmental regulations.
w Clean the sealing surfaces of the oil separator tank.

Attentlonl The ollseparating cailridge ls dlsposable and cannot be cleaned.

w lnsert the new O ring (9) in the groove in the oil separator tank.
w lnsert the new oil separator cartridge (8) with new gaskets (6), fit and tighten down the
cover plate (5) with the hexagonal bolts (4).
w Flenew the screen filter (11) and the gasket (10) when the oil separator cartridge (8) is
renewed.
B Remove the nozzle (1) from the hose coupling (2).
B Close the left-hand and,upper access doors.
B Open the shut-off valve between the compressor unit and the user's pipework. .:

A
#
i
The metal parts of the oil separating cartridge are electrically conduc- 'l
tive and thus require "electrlcally conductlve gaskets". The gaskets (6)
are fltted wlth a metal clip (7) that fulfils this requirement and provide
an electrlcal path from the oilseparator tank to the frame of the com-
{J
pressor unit. J

Do not remove the metal clips.

A Carry out a trial run.

When the e is reached (see chapter 1.1) shut

down the. chapter 8.2) and lock out the maln
switch toi compressor run.

Aftenvards, catry out a visual check for leaks. .

,
,

9-35
 DESPATCH NUMBER

DESPATCH DATE

ACCOUNT NUMBER

CUSTOIUER ORDER NU[/IBER

ORDER DATE

1 ?6(i0(JEU5 (.5. <so HF,L INT. SLRU ICE HiI SPiII-SF',

3E(l0r:'934 l?'l . 7g HF.t] SL]F. SEIIV]UE KIT $H13_5Hi1
/

L/kr( \f
A MEMBER OF THE ECONOMATICS GROUP
Registered 0flice:
EC0N0MATTCS (TNDUSTBTAL) LTD.
EPIC HOUSE, DARNALL BOAD,
ATTERCLIFFE, SHEFFIELD 59 5AA U.K.
TELEPHONE: (0114) 281 3344
FAX: (0114) 243 9306

e cf, r-1
a n t t o kn U W on a) EB
 I(AES
COMPRESSORS
Spare Parts and After Sa es Seruice

10 Spare Parts and After Sa es Seruice

10.1 Service parts and expendable parts

Description No. off Order No.

Oilfilter cartridge 1 6.1985.0 q6ooolot
Air filter cartridge 1 6.2003.0

Filter mat 1 6.1943.0 q6ooe 3a5 Kzg't r

Oil separator cartridge

Complete set 1 6.2008.1

Comprising:
Separating cartridge 1

Gasket 2
O Ring 1

Dirt screen filter 1

Gasket 1

aEe-vt CL= KtT q6oocjaoq R6o 6t

R COBURG 5uPPi LI il\ETvI AR,Y q6oooa3L *ies
KOMPBESSOREN GERIIANY 3€?vtc€ LtI E6

Ir,4odel
5K tq E Year
max
vJorkrng
preS3ure
No
bar(g)

o, .6 eos
Povuer

Air a"
E
u"rVI lrn n

lmponant for all queries:

@ Enterthe data on the cornpressor name plate in the name plate shown above.
Always quote the data on the name plate when making a query or ordering spare parts

Attention! AIways order origina! spare parts from the compressor manufacturer
to avoid lower quality spare parts in your compressor unlt.

10 - 36
lp
rtr
(7)
I
3
On
EE
(g
T3
.x
!,
tr
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F -
F
 t ( 5

EtectricaI diagrams
[ompressor SK 19
400V 50Hz

Manufactuner: Kaeser Kompnessoren GmbH

Postfach 2143
9 6t-10 [ ob ur g

0rlm lo.09.l9tt fover page

Slllrr KAESER
Compressor SK
t00v lt,lt.r( , XOHPRESSOREN 19
DSK19-099r. /00200
ll
D.iui Lrn. l{orn [rrrlr drrh Irrrlr lllrr
'ts &rrdr{l r{, ll!trI rlrrp tlrrJl txll trfl inl?0
r llet0 00200/ 1660-6t)tsz --t,a 'd.o I
6t ys JossaJduol Nlu0ssludH0x
r.llls 'qr.€ q
slueluo, J0.lqel U]S]V) t66a'60'01 rnl!0 ,

l 00200/r660-6tvsY alEld 6u!lunour {no-IEl $

t 00200./t,660-61)lsx AllX- dlJls IPUlrrJal uo!llauuor lPuluJal zl
z 00200/t660-6tys)t Alx- dlJ.ls leuluJal u0!lrauu0) leuluJal t1

t 00200,/t660-6|,)lsx lx- dlJls leuruJal u0!lrauu0, leuluJal 0t

l 00200./?660-6|,)ls9 elPld 6ullunour sa)l^aP ,o lrll rlJed 6

t0 00200./?660-6t)tss a)!^ap ,o loquls 6u!Ir!lu.p! s

5 00200/?660-6t)tss slrEluo) aaJl-llo^ ueJ6?lp llnrr!) L
t 00200/i660-6txss Ja^oe6uEq) ellep-Jels ureJoelp l!n)J!, 9
E 00200/?660-6txss sl0Jlu0) ueJ6rlP l!n)J!, 5
z 00200,/t660-61xss uo 6url)ltAs ureJ6P!p lln)J, t
l 00200/r660-6txss llun JaAod ureJ6elp llnr4l t
l 00200/t660-6tysz slualuo) lo irlqel z
I 00200,/?660-6rxs0 a6Pd Je^ol I
uql 6rs.p llun 6ed lJiJnl)eJnueul'01 6u6e:g (rau,o{sn)l 'op 6u1eug aureil .0ll
u.rp!.zw.lu.6 pv llrlg lJ.llrlrr.Hl rauunus6unuqrrr2 lapun)ll Jauutnus6unuqraT 6unuuaulg Jil 'Pl'l

E r- E , I El t-
-l
 tEl 6 5

_._. PE

t
H07V-K
-x1 2.5mm'blark

H07V-K
6mm'blark -00
F EI
I
c
0,t -0.63A [----
adjusted:0,65A

H07V-K

H()TV-K
l,5mm' black
2-5mm'blark
-T1

t00vA
U 2l0v
-x1 J c -K1M I 3 -K2M I 3 5 -K]M I 3 5
/L.2 / \.3 / L,\
ttt 2 \ l. 6 2
lll H0rv-K Secondrry sid: ir :rrlhcd.
lll 2,Smm'blark + ll the slrrling link
trt -x1 is renov d. insulrtion
-F2 moniloring nust br

Hain svilch,
'-i-t{
ttl
'B-r9A
a
inslalled
EN 6020t-l
Fuse supplied trt
by user ttt I

NYSLY(i-J NYSLY6-J
-x1
irtmm'
,'^+ { il
ix4 mm'

lll /2.1
tll I

lll wt v2
ttl I
M U2
tll l- w2
lll
lll -M1
tll I

LI L2 L] PE 1l kw
r+00Y /3/PE/50H2 Iontrol tabinet viring:
See service manual for All non-hbe[rd control linas rrr
supply cable tross-serlion tmm'red H05V-K

Fwlloft Compressor molor 210Y/l-/S0lj't

6rurg ol luNlloru: Hain pover supply Pover supply unil (onlrol vollage lapping
tl 0rlun 10.09.t9rt (ircuil dirgram
E..rb. 5illrr KAESER
b

r | (00V Il.tl.9t KO}IPRESSOREN Iompressor SK 19

sl 6.0a. Blrlt t
0l Andtun! 0.lur N.0a Norn [r!.lr du(h Irrrlr llirr tfrrprmg A5X00100 Power supply unit ssKl9-0991 /00?00 Et.
 2 3

/1.8 -x1 80 -x1 I -r1{5

-s10
door limit syilch
p
lef t

-s1 _sl -x1 8t

6:- --{).6 -x'l E2

0 = ST0P/Resel EHERGEHIY STOP
1 = START

-512
door limit syilch
p
lop

-x1

-AOt l
-X1W l5 -x1w 16

-x1w t5
-x1w 16
-x11W -x11W

/1.8 /r.1

lur llort EHERGENIY 5IOP inlerlork lenance doors closedl

9u4 ol lwlhot svilching on <hain
0rlur r0.09.t9rt cirruit diagram
8.rt. KAESER
XOT,IPRESSOREN rompressor sK 19

D.l!r lhrr llrr trlt dr(h A9(00200 switching on ssK 19 -099/.,/00200 Bt.
 l ( 5

-xH -x1 -x1

-t2 -811 -K1M -92

/1.) E-- / \.2 E} J
>t00'c 0,1-1,2 2
brr

-x1 1 -x1 t -x1 s _s3 2t

/2.s1---
22

21
-K1M a
/1.2
22

-slt2

l
-401
AI s1 a s2 a sl a ST a s5

FAILURE: Sl nolor

+ ON 52 lenperature
SJ direction of rolation
S[ for addi]ional
A2 t{
release lo(ked: 55 rounter pres3ure

€€
hh

-x1 03
/2.8

lurllm no lailure f ailure/maintenance indications

gru4 rl lnlbor: rontrol s
lblur l0.09.t rt circuit diagran
Sill:r KAESER
KOHPRESSOREil compfessor sK 19

0.1 Lr. llrr Er!.lr dr(h llhr tontrols 5SK19-0994,/00200

 F r 2 :t

-xtl -x1 t,

15 -81 fl
-K1.27
mains Pressur! 12
6 t6

-x1 t9 -x1
-K1M tl -K? 1l
2
Lt,
7
t( -x1w re -x1w
-xlw t9
-X1l'/
,2t{
-X1lW'*/tc -x11W

-K1M tl -K]M tl -x11W

tt
2 -K1.17 25
1( t1 t -xlw tc
20 lo.t -x1w 10

-K3M 7l -K2M ?t
4 3 -K2M
22 72 l

-x1

A1 AI 1 AI
-K1M -K2M -K]M -K1.rT -K1.27 -K2 -Y1
At A2 2 AZ
-x1 02 -x1 ot
/J.8
I min.

te
t5 l

lurllon service hours slar conlarlor htet/ venlino

lurllort mains contaclor della ronlaclor star-della lime idtinq lime pressura lov
9ru4 cl lmlloor: slar-della rhangeover pr:ssurc ronlrol
rl Drlur 20.09.tr9t circuil diagram
6rrb. Silitr KAESER
bl
x0HPRtss0nEH rofnPressor 5K 19
rl d. Blrtl t
A.daruE D: lur llllr llrr frt.lr dr(h frrrlr llirr t.lrp(rE: A5X0Olo0 star-delta (hangeover SSKl9-099I../00200 Bl.
 FT 2 l
-tE-f

vott-free contacts
connection by customer

2t
K 1M 5l
t.2 -A01
5( /1.7

-x1w r -XlW
o
z -X1W l -x1w r -X1W

all lines not designated,

l.Smm' orange H07V-K

lurlirn molor running no failure

9ru4 ol lmlbu: voll-free conlarls
rl D.lur 20.09.rr9t circuit diagram
bl &rb. 5lllrr KAESER
compressor SK 19
rl c.r. .z'( r . KOIIPRESSONEH
Elall
0l lndcm D.lu. Lrr lldr trr.lr drrlr frrrh llh: thrDruo 45X00200 volt-free ronlarts 5 SK 19-099rr,/00200
5
Bl.
 I 2 l l- --e.-

-A01 matfunction relay -T1 controI transformer

-81 mains pressure switch -x1 terminat strip

-87 hour meter (service hoursl -X1W terminal strip "volt-free contacts"

-K2 auxitiary contactor -x11W plug connector 5-pote, (-X1W)

-K1M mains contactor -Y'l control valve

-K2M delta rontactor
-K3M star contactor
-K1.17 slar-detta time detay retay
-K1.27 off-load time relay
-M1 cornpnessor lnotot' malfunction indicators
-00 motor protective switch, control I rans former
-F2 overload relay
-51 contro[ switch shutdown
-811 distance thermometer
and
-sl emergenry pushbutton
-82 pressure switrh for direction of rotalion indicating f unc tion
-s 10,- s 12 door limit switrh

.l 0.lur lo 09.199t idenlifying symbol of device

bl 0crb. Slllrt KAESER
l(0HPRESS0ntN compressor SK 19
rl 6.oa. /<-t Elall ot
tl Andcur Drlur lln Lar [rr.]r dr(lr Enrlr llir: (}tDrulc A5l(00100 ssK 19-099r,,/00200 Bl.
 3

A B t 0
Conrerns only lh ntnul clurrr
E F 6
Fabrikatsbezeichnuno Sironlaulplan Wst.-Nr.
Stiick- Benennung und Verwendung Irp; l.rl.ll-lt.i
thlrhgr+}t.; fil*rbrnkhrhg L fd. Belriebsmil lel-Kennr. Einbruorl
mlv.Dd{. l.dn 0.1m. r D. slM.prrrr{, t..qnr, Ihtl.llb.r.kh uh tll l0rt. I.l I Planabschnll t
z ahl
H I ) x
Description and function ldentification data Nr. Schabl, 8Z- VA
ldenlifying symbol Eingrngs-
Irprl oder llo; rltmtl&; rdprnl rodr )b.; lrrk khnld d.l. ct d.rk. (ircuit diagr:nm
o tv. Item rbrl llcl rxllco ll..
Locrtion Nr Pos. Kz. .l vrrm:rk

Hounling plale ( 75x 260x1 2.8202.t cK(

2 Holor conlactor B t6-10-10 7.208t.0 ABB .KIH.-K2H
Holor conlactor B9-10-10 7.1210.1 ABB -xltl
Auxiliary svilch tA 7-22t| 25, 20E 7.186t.0 ABB -KIH
2 Auxiliary svilrh (A 7-01 l0E 7.2019.0 ABB -x2r.r.-K3l,l
I 0verload proleclion T25 0Ut9 1l-19A 7.2052.r A8B -F2
I [ombined time delay relay S6KAE 5 2-20sec.1,5-l0min 7.3999.0 Srharro -K1.1t / -K1.2t
t Holor overload proleclion svikh HS 325-0,61 0.(-0,61A 7.1 s25.0 ABB -00
1 Auxitirry contartor K6-222 230V 50,/60H2 7.2088.0 488 -x2
[ontrol translormer r00 vA 115-1.00,/230V 7.0777.1 Ei18 TI
I Terminal slrip 7.3098.00010 Wietand -xt
Trrminrl slrio. inrl. Pluo connorlion 5 oole exl. <onnacllon ?.l9l].0 Wlslrnd -xltr.-xttw

I Conlrol panel
t (onlrol svilch ls 7.01.26.0 A ssmann -st
I Distanre temperalure qauqe 0- 120l 100'( E.0191.0 S I tirk -8fl
I Hour meler BW40 2l0V 50Hr ?.0702.0 Hiiller B7

I Alarm relay ENO T2lK 230V 50./60H2 7.1767.00050 Zander -A0l

t EHERGENCY ST0P-Butlon 208 7.1290,00010 Assmann S]
1 Pluq connection 8-pol e 7.271 3.0 Phiinix -A0t
1 Pluo tonneclion 3-pole 7.39t 5.0 Phtinix -401

!.1lhd$.!t.ll6l rd 66tlo ud ltrrctSar lhd.lh h d.n rtrt E.nd.laSr.ltm I ud ( Igrgebrm ortm Ytn md..h lfr rq/F.nl, il drlt mlctrd !y lha h..r, ltrt ot <drmr ! md ( rlq/d br rtrlrd. h .l Vru&rurlrill - Imrktn
atrutiLG tI. Drlm h dm sp.alm 0 blr li rhd rurllrlkh ulr lLErng d.rr Grllrrtiklllrho-llrx .ddlho. th rhlr h rdmr 0 to 6 tlEld br glvm lcarthr ylth lL Ic. !l llJt lh, ol rqrJgrml. hrcir tr
htu9.b6. !.y.il ti d. B.htyrluE t.ddldr n!(ltr.g.i tl.khlrc fiir [rt.lrl.lb.rl.llr9 llt tutllrlkh ttx, r h.lptd h mroil txhd<J m+ihr. lnm r&rtrg rgrr prlr.lto w.l. th. lEld ,lo. o, ttr.
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h 2vrlfulrillm d. d.rrlr(h. Ihr 6rrrn rrtloo.gdL. h trt.r !, dqil.
0rlun 20.09.t994 Equipment parls lisl
B..rb. Sil trr KAESER
6rpr. KOI|PRESSOREN Iompressor SK 19
Bl:ll t
0.lun l{rmr llorn [rrrlt durrh: [rrrlr l0r: l.lr!prung.45X00100 Mountinq plate 65K19-0991 /00200 8t
 destination destination
c.bte-no. terminaI strip cabtr-no.
external inside
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b termin aI strip: -X1
€ total 29 tarminals
controlter PE /1.1 -tt'l PE
suoDly lin! PE /1.2 -r.tl PE
suppty line L1 /1.2 -K2H I
supply line L2 /1.2 -K2t,l l
suooty line L3 /1.2 -K2t1 5
-sto fl 80 /2.7 -s3 1l
-sro 12 81 0 /2.7
-s12 11 824 /2.1
-s12 12 830 /2.7
t /2.8 -F2 95
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x -82 1 la /3.5 -A01 Sa
X -82 2 ( Tr. /1.t, -Klt't 32
X -82 I 5 /3.5 -Klr1 21

-Yt 6 / 1.7 -K2r',t 16

a
X -Bi1 2 7 /3.3 -Aot s2
-B1 fl 17 / \.7
-Bl 12 32W / lr.1 -x1w 32W
-Bl l! 19 /t .5 -Kr.2T A1
-Yt 01 ? / lr.1 -T1 0
-oI x 02 / 1..2 -KlH A2
! 03 /3.2 -A0r A2
r rn 0ra /1.7
l,.r)
o
E rn -81 PE PE /1-7
6
n -82 PE PE -TI PE
-Yt PE
-B1I PE PE mountinq plate
PE -x1\{ PE
PE

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 destination destination
cablE-no. terminal strip <abtr-no.
erternal inside

c
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o =
o o oto =
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c a e a 7 o 3 =
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a o t, o o o
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terminaI strip: -X1W
I € tota[ 17 terminats
1l I /s.) -K1M 53
=3=
oor 2 /5.L
1l 3 /s.\ -K1rl 51
=cF
E,O 2l l. /5.5 -A01 21
)=
.)c 2l 5 /5.5 -A01 22

J. zl 6 /s.6 -A01 2\
o 15 I /2.L -s1 11.

E -xl1w 15 1sa /2.\-

16" /2.5 -s3 12
o
= -xl'tw 16 164 /2.5
r
18? / 1..7 - -K2 A1

-x'tl\{ rE 184 / 1..7

o / L.7 -
32Wl -x'r 32w
G
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19? / lt.6 -K1.2T Al
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PE .XI PE

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Brrb. KAESER
KOHPRESSOREII comPressor sK 19
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KAESER
COMPRESSORS
Append x

11.2 MaintenanceSchedule
Seria! number ol the compressor unlt:

Date Description of work Operating hours Signature

11 - 38